Alkaline primary cell



May 30 1950 H. E. RHODES ALKALINE mmm CELL Filed Nov. '7, 1944 29 25 INVENTOR.

Patented May 30, 1950 P. B. Mallory & Co., Inc., Indianapolis,` Ind.,a

corporation of Delaware l Application November 7, 1944, Serial No.` K

(CL 13s- 111) 12 Claims.

'Ihis invention relates to primary cells.

An object of the invention is toimprove the construction and composition of primary cells.

Other objects of the invention will be apparent from the description and claims.

In the drawings:

Figure 1 is a top view of a primary cell embodying features of the present invention;

Figure 2 is a cross section thereof Figure 3 illustrates a battery of cells;

Figure 4 is a section of a cell of dierent construction; and

Figure 5 is a detail of the vent construction of the cell of Figure 4.

A feature of the present invention resides in the use of an amalgamated ferrous metal terminal for the zinc electrode of the cell. 'Ihe invention also contemplates an improved cell construction, and an improved vent construction.

In primary lcells of the zinc-alkali-oxide type one electrode is of zinc, the other electrode of a depolarizer oxide composition such as mercuric oxide or cupric oxide mixed with graphite, and the electrolyte an aqueous solution of an alkali such as potassium hydroxide and may also contain the alkali zincate. In one construction of such cells the depolarizer is pressed into ythe bottom of a steel container and a zinc top disc terminal is sealed in the top oi the container with a, neoprene or rubber sealing grommet, the top beingl in contact with the zinc electrode inside the cell.

It has been noted that unless an extremely high pressure seal is maintained between the grommet and the zinc top there is a tendency for the alkaline electrolyte to creep along the zinc surface under the grommet to the outside ofthe cell where the combined effects oi the alkali,` air.

moisture and C0: produces corrosion ofthe zinc. 'Ihis creepage tendency appears to be specific to zinc. as no such tendency has been noted between the surface of the steel and the grommet member. If a strip of zinc is partially immersed in an alkali electrolyte the creepage of electrolyte above the surface occurs rapidly. On the'other hand if a strip of steel is partially immersed in electrolyte this creepage does not/occur,v

Heretofore it has been considered necessary tomake the top or terminal'member which is in contact with the zinc anode of the cell out'of zinc or a metal having substantially no potential diierence with zinc when immersed in the cell electrolyte. For example, it has been considered impossible to use iron orsteel in contact with the .6 volt between plain steel and an amalgamated or unamalgamated zincelectrode. The potential difference between' plain steel and amalgamated orl unamalgamated zinc `generates `a current between these two metalsand the zinc is gradually corroded while at` the steel electrode hydrogen gas is generated. The corrosion of the zincwould normally not permit the use of a steel electrode in contact with the zinc but when an attempt is made to hermetically" sealv the cell then further difficulty is encountered 'because of the internal gas pressure developed by the release of the hydrogen at the steel electrode.

I have made some experiments in which. I have found that by treatment of the steel the above effects can be eliminated.` By treatment of the steel for a period of about 30 seconds at 60 C- in-an aqueous solution containing 5%v of mercurio nitrate acidied withabout 1% oi nitric acid I found no reduction in the open circuit potential diierence between the two metals butvI dlid find a marked reduction-in the generation of gas. 1f a piece of plain steel and apiece of zinc are connected together and immersed in an alkali electrolyte a rapid evolution of gas at'the steel electrode is immediately evident; if the steel is pretreated in the mercuric nitratenitric acid solution then there is `no visible 'generation of gas and only very small amounts'of lthe gas can be detected ever relatively long periods of time.l

I have now found that if the steel electrode is provided with a'thin surface layer of amalgamated zinc no gas is vgenerated when the treated steel is placed in contact with the zinc electrode in the cell electrolyte.` This makes possibleV a primary celll constructionhaving a treated steel terminal in contactrwith the' `zinc electrode andlif desired another steel terminal 'in contact with the depolarizingelectrode. Thel amalgam coated vsteel terminal not exljlibit` the electrolyte creepage and corrosion tendency of "a zinc terminal.` y t 'Remiriniz` to4 the unimi;iis-1v Figures 1j and 2 illustrate a flat cell'constructin I have devised which embodies suelta' terminal as well as other novel features.` 'I'he cell comprises a circular ilat metal cup I0 formed offcold'rolled steel which The inside surfaceoi.' this cu`p` is provided with zinc because of 'thepotential difference` of `.5` to 55 the zinc amalgam -efcatingi'sownich `may be applied byj rubbingl itpwith `rimingannarei "zinc, tumbling itY with amalgamatedzn powdenpr by other methods;v 'lhe'lzincfelectrode "ofthe cell comprises andainalgamated zinc which nfs snugly 'into i-lbtiolf quil L10-Q The preferred method of producing the amalgamated coating on the steel is to first treat the steel electrode in a plating solution to produce a zinc coating of from .0001 to about .0005 inch thick although heavy coatings can be used satisiactorily. The pre-plated steel is then placed in a solution containing a mercury compound. One example of such a solution is the mercuric nitratenitric acid solution previously referred to. Satisfactory amalgamation is also obtained in an aqueous solution consisting of 100 cc. oi water, 50

to '15 grams of potassium hydroxide and 3 grams of mercuric cyanide. The amalgamation procedure may be done at room temperature for a period of approximately 1% minutes or it may be done at elevated temperature at say 60 C. in approximately 30 seconds. After amalgamation it is desirable that the parts be washed in a solution consisting of 100 cc. of water and 50 to 'I5 grams of potassium hydroxide. The washing may be done at room temperature and should be followed by a wash in pure water to remove all traces of alkali. The above amalgamating procedure will produce a zinc amalgamed coating containing between approximately 3 and 10% oi mercury.

A circular neoprene or rubber sealing member I2 rests on top of the zinc electrode and against the vertical peripheral wall of the cup III and carries within its central aperture an electrode and spacer assembly comprising depolariz- 'ing electrode I3 formed of a mixture of mercuric oxide or cupric oxide with about 10% of nely divided graphite pressed into a shallow pie-pan shaped steel cup I4, the flange I5 of which fits within an annular groove in the inside of the grommet I2. A disc I6 of diaiyzing paper covers the surface of the depolarizer I3 and three discs I1 of porous paper such as an alkali treated cellulose paper, kraft paper, iter paper or the like to nil the remainder of the space between dialyzing sheet I6 and the surface oi zinc electrode II. The paper sheets are impregnated with the primary cell electrolyte which may be a 43% solution of potassium hydroxide which is substantially saturated with the alkali zincate as described and claimed in Samuel Ruben application Serial No. 486,367, led May 10, 1943 now Patent No. 2,481,539, issued September 13, 1949. The sheets contain sufficient electrolyte to provide eiectrolytic conductivity therethrough but insuflicient to provide any free-flowing electrolyte which can run out of the spacer. The top flange I8 of cup I0 is turned or spun down over the top surface ot grommet I2 to apply compression thereto and complete the cell assembly. Cup I0 comprises the negative terminal ot the cell and cup I4 the positive terminal. While the outer surface of cup I4 is shown substantially ilush with nange I8 in the completed cell, it is contemplated that in some cases the surface ci cup I4 may extend slightly above the flange s0 thatseveral of the cells can be stacked up to provide a series connection of the cells to form a battery.

Figure 3 illustrates an assembly of this type having protruding positive terminals Ila and provided with spacing rings Il of insulating material to insure against short circuiting of the cells at the edges. This structure permits the assembly of cells in series without the use o! any interconnecting leads ordinarily needed in making a series combination.

While cells of this type display no generation ci gas under normal conditions of storage and polarizer oxide to 0l' 00PM Some 885 mains in the circuit which current is still s EFE ai gasi pleteutilizationofthecelkinthe battery beforediscard.

Figures4and5illustrateaventappliedto anotherprimarycellstructureasteei can 2| having depolariner 22 pressed into the bottomthereof andapremedlayerofpws inert material such as um silicate. magnesium hydroxide or otherinertpowda'overthe depolarizer. A paper layer 2l is over the met layer and the anode assembly 2l commises ardl ofalternatelayersofzincfoilnandpompsper 33 impregnated with electrolyte. Theoutermrface of theroll is covered with arrirnulatingaheet or layer Il. Thetop mayalted disccoatedwithzincamalgamllandthesealing member comprises a rubber or neollme grommetll spununderthetopedgeotthecln andrestingonashoulderofthecan.

The vent construction inthis cell camilla hole 28 piercedinthecenterorfthebottllld thecanll whereitiseompletelycovedbytin depolarizer. Figure 5 shows the vent camtrnctioninmagniileddetail. Toprovideafurtha' sealathindiscorlayerllofneoprenecanent closestheholeinsidethecan. Thisnnintaill asealuntilgaspreureisgenmted.

Theamalgamcoatedironorsteelte'mhnld thezincelectrodepermitsofaeell which is free of liability o1 electrolyte creepale. andofexternalcorrosion. Italsopermitsilnproved cell structures, duetothehigherstrength available in the negative terminal member.

The construction shown in Figures 1 and utiiizedthestrengthavailableinthenegative terminalinanimprovedstructme. Byclamplng thezincelectrode Ilunderthesealinggrommet the electroylte is largely confined to the active faceofthezincandowtothejointbetwemn zincandtheterminalcupllisretarded.

While specific embodiments of the inventlm have been described, it intended to curval tl invention broadly within the spirit and seque oftheappendedclaims.

Whatisclaimedis: Y

1. A primary cell a iirst cup c( i'errousmetal,ane1ectrodeinthebottomtheeot. aporousspaeeroversaidelectrodeandanctrolyte impregnating said spacer, a second cup of ferrous metal of smaller outer dimensions than the inner dimensions of said first cup, a second electrode of opposite polarity to said first -electrode in the bottom of said second cup, said secmd ycup being faced into said first cup with said second electrode in contact with said spacer,

an insulating sealing ring spacing the outer edge of said second cup from the inside wall of said first cup and sealing the space between them, and an amalgam layer interposed only between the inner surface of one of said cups and the corresponding surface of the electrode in said cup.

2. A primary cell comprising a zinc electrode, a depolarizing composition electrode, a porous spacer and an alkaline electrolyte impregnating ,said spacer, and a case for said cell comprising tween in contact therewith, and an amalgam layer interposed only between the inner surface of one of said cups and the corresponding surface of the electrode in said cup.

3. A primary cell comprising a steel cup, a coatingof zinc amalgam only on the inside surface thereof, an amalgamated zinc electrode disc in the bottom thereof, an elastic insulating sealing ring resting on said Zinc disc adjacent the side wall of said cup, va porous spacer comprising a plurality'of porous discs resting on said zinc disc inside said ring,`an alkaline electrolyte impregnating said spacer, a second smaller steel cup faced against the top surface of said spacer and having a, flange extending into an annular groove inside said sealing ring, and a depolarizer composition of a -reducible metal oxide and a conductive inert material filling said second cup and in contact with said spacer, the edge of the first mentioned cup being turned down over said sealing ring to apply pressure thereto and seal said cell.

4. A primary cell comprising a' steel cup, a

lining of zinc amalgam coating only the inside.

thereof, la zinc electrode in the bottom thereof in contact with said lining, a layer of porous spacer material on top ofsaid zinc electrode and an alkaline electrolyte impregnating said layer, a depolarizing electrode over said porous layer and an inert metal terminal layer in contact lwith the upper surface of said depolarizing elecf trode, and an insulating sealing ring sealing the space between said inert terminal and said steel cup.

5. A primary cell comprising a steel cup having an inturned rim, a lining of zinc amalgam coating only the inside thereof, a zinc electrode layer covering the bottom thereof over said coating, a sealing ring of compressible insulating material resting on said zinc electrode near its outer edge and compressed under the rim of said cup, a layer of porous spacer material resting on said zinc electrode inside said ring, an alkaline electrolyte impregnating said spacer layer, a layer of depolarizing oxide composition resting on said spacer layer, and a top steel disc covering said 6 depolarizing layer and held at its outer edge in an annular recess in said sealing ring.

6. A sealed alkaline primary cell comprising a` pair of terminal members, an insulating sealing member clamped between cooperating surfaces of said terminal members and constituting therewith the enclosure of the cell, one of said terminal members being formed of ferrous metal and having a layer of zinc amalgam only on the inner surface thereof. an amalgamated zinc electrode in pressure contact with said layer of zinc amalgam, a depolarizing electrode in contact with the other of said terminal members, and an alkaline electrolyte in contact with said electrodes whereby electrolyte creepage to the outside of the cell under said sealing member and along the outer surface of said terminal member of ferrous metal is positively prevented.

7@ A sealed alkaline primary cell comprising positive and negative terminal members of ferrous metal, au insulating sealing member held compressed between cooperating surfaces of said terminal members and constituting therewith a generally huid-tight enclosure for the cell, a layer of zinc amalgam only on the inner surface of said negative terminal member, an amalgamated zinc electrode in pressure contact with said zinc amalgam layer, a depolarizing composition electrode in contact with the inner surface of said positive terminal member, and an alkaline electrolyte in contact with said electrodes, the outer surface of said cell enclosure with the exception of' the sealing member being constituted of ferrous metal whereby electrolyte creepage to the outside of the cell under said sealing member and along said outer surface of the cell enclosure is positively prevented.

8. A sealed alkaline primary cell comprising a 4pair of terminal members, an insulating sealing ring held under compression between cooperating surfaces of said terminal members and defining therewith a normally fluid-tight enclosure for the cell, one of said terminal members being formed of steel and having a layer of zinc amalgam only on the inner surface thereof, an amalgamated zinc electrode in pressure contact with said layer of zinc amalgam, a depolarizing electrode in contact with the. other of said terminal members, and an alkaline electrolyte in contact with said electrodes whereby electrolyte creepage to the outside of the .cell under said sealing ring and along the outer surface of said steel terminal member is positively prevented.

9. A sealed alkaline primary cell comprising positive and negative terminal members of steel, an insulating sealing member held compressed between cooperating surfaces of said terminal members and constituting therewith a generally fluid-tight enclosure for the cell,'a layer of zinc amalgam only on the inner surface of said negative terminal member, an amalgamatedl zinc electrode in pressure contact with said zinc amalgam layer, a depolarizing composition electrode in contact with the inner'surface of said positive terminal member, and an alkaline electrolyte in contact with said electrodes. the entire outersurface of said cell enclosure with the exception of the sealing member being constituted o f steel whereby electrolyte creepage to the outside of the cell under said sealing member and along said outer surface of the cell enclosure is positively prevented.

10. A sealed alkaline primary cell comprising positive and negative terminal members of ferrous metal. an insulating sealing member held compressed between cooperating surfaces oi'- said terminal members and constituting therewith a generally uid-tight enclosure for the cell, a layer of zinc amalgam only on the inner surface of said negative terminal member, an amalgamated zinc electrode in pressure contact with said zinc amalgam layer, a compressed depolariaing composition electrode in contact with the inner surface of said positive terminal member, and an alkaline electrolyte in contact with said electrodes, the wall of said positive terminal having a perforation therein normally covered by the compressed depolarizing composition to provide an emergency vent for the cell upon consumption of said composition when the porosity of such composition increases.

1l. A sealed alkaline primary cell comprising a cup of ferrous metal having a perforation in the bottom thereof, a dcpolarizer composition electrode pressed into said cup, a zinc electrode in- 20 side said cell spaced from said depolarizer, an immobilized body of an alkaline electrolyte interposed between said electrodes, a terminal memev ber of ferrous metal having a layer of zinc amalgam only on the inner surface thereof; liri'pressure contact with said zinc electode,-and an insulating sealing member compressed betweencooperating defining therewith a generally f luidetifght4 enclosure for the cell, the perforation in' said'cup being normally closed by said compressed depolarizer tlally consumed and becomes porous.-

'f` l .v v

. s 12. Asealedalkalinedrycell comprisinzarst cup of ferrous metal having a depolarizing cathode electrode in the bottom thereof, a second cup of ferrous metal having an amalgam layer only on the inner surface thereof, a zinc anode located in said second cup and in contact with said amaigam layer, an immobilized electrolyte in contact with said cathode and anode, and an insulating sealing ring compressed between intertted and spaced marginal portions of said cups deilning with the cups a sealed enclosure for the cell.

HOWARD E. RHODES.

REFERENCES CITED le of this patent:

UNITED STATES PATENTS Number Name Date Re. 13,174 Morrison Nov. 22, 1910 428,684 Mason May 27, 1890 618,993 Paget Feb. '1, 1899 1.331,456 Ellis -v Feb. 17. 1920 1,511,153 Benneret a1.'-.. Dec. 21, 1926 1.644,34! Martus et al. i Oct. 4, 1927 1,920,799 lLilienfeld Aug. 1, 1933 2,111,041 Brennan' f Mar. 15,1938 2,422,046 'Ruben June 10, 1947 FOREIGN PATENTS 'Nuniber f Country Date `324,415 1 VVGreat Britain Jan. 30. 1930 14.532 I `ouest Britain Aug. s, 1934 

5. A PRIMARY CELL COMPRISING A STEEL CUP HAVING AN INTURNED RIM, A LINING OF ZINC AMALGAM COATING ONLY THE INSIDE THEREOF, A ZINC ELECTRODE LAYER COVERING THE BOTTOM THEREOF OVER SAID COATING, A SEALING RING OF COMPRESSIBLE INSULATING MATERIAL RESTING ON SAID ZINC ELECTRODE NEAR ITS OUTER EDGE AND COMPRESSED UNDER THE RIM OF SAID CUP, A LAYER OF POROUS SPACER MATERIAL RESTING ON SAID ZINC ELECTRODE INSIDE SAID RING, AN ALKALINE ELECTROYLYTE IMPREGNATING SAID SPACER LAYER, A LAYER OF DEPOLARIZING OXIDE COMPOSITION RESTING ON SAID SPACER LAYER, AND A TOP STEEL DISC COVERING SAID DEPOLARIZING LAYER AND HELD AT ITS OUTER EDGE IN AN ANNULAR RECESS IN SAID SEALING RING. 